Concrete, masonry and steel construction



vMaly 26, 1931.

J. J. OREILLY CONCRETE, MASONRY, AND STEEL CONSTRUCTION vFiled June 25, 1927 "asm:

Patented May 26, 1931 JOHN JAMES OREILLY, OF NEW YORK, N. Y.

CONCRETE, MASONRY AND STEEL CONSTRUCTION Application filed June 25, 1927. Serial No. 201,573.

This invention relates to a method or process of fabricating, manufacturing and erecting sections of building material to formfa wall, partition, Hoor slab, beam, girder, col-l umn, or other unit, or partthereof,` with facings'of anynatural or artificial building material by the means outlined hereinafter, and has for its object to render the fabrication, manufacture, and erection of said units l0 of building material more expeditious dependable,l and among other things cheaper, by minimizing the amount of skilled labor and expensive materials necessary to obtain the end desired.- z 1 V Briefly stated the method or process yconsists, mainly, Aof reheating'steel or other metals and imposing a fireproof covering on one `or both sides of same, or of imposing the 'ffireproof materials` on` the metal while it is Y .20 heated' in the original process of manufacures #12 and 3 are vertical sections thrudifferent types", of wall construction; 1 Figure :#:4 is a section rthru abeam, girder or column of hollow construction. Figure #is a plan -view of part of an exterior wall showing an externalfandan internal corner, an vexterior pilaster, a window reveal, and a rabbeted jamb. Figure #6 is a vertical wall section showing the construction of a sill and a heavy cornice. Figure #7 is a vertical section thru a floor slab, showing Va single interior partition above, and a hung ceiling anda double or hollow partition below. y

The letter a in the drawingsindicates the fireproof .covering over the metal backing .45 indicated by the letter c. v'Iheiletter l) indicates a bed joint between the units. The letter S indicates a hollow space formed by assembling different pieces of the fireproofed metal.- Similar symbols throughout refer to 30 similar parts.

.In Figures itl-QOfand 21 are the top and bottom connecting points `for the units shown with Vsmall filler pieces (23) interposedv between the sections to allow room for a mortar joint vbetween different sections; The symbol 1.5 indicates wire lath or additional reinforcing for the fireproof covering.

In Figure ft2-2 indicates a double channel formed by putting two sections together in the field. Y

In Figure #gt3-1.4 is a layer of wire lath or reinforcing for the fireproof facing,'cet indicates the metal backing, and S3 is a small hollow 'space between the facing and the metal backing which may be filled with light insulating materials such as asbestos. 'In

lthis case the fireproof facing issecured to the metal backing by means of the lath or reinforcing 1.4.

In Figure #4402 indicates the top of a beam or girder which in this case may not be fireproofed. The shape of the hollow section may be changed4 to adapt itself to any nel e-Figure #2. The symbol a1 indicates an external corner, a2 an exterior pilaster, a3 a window reveal, ze a rabbeted j amb, and a5 aninternal corner.

In Figure #f6-a8, e9, and al() Vindicate an exterior cornice, and (1.12 indicates a window sill.

In Figure :iT-,S2 indicates a space between the floor slab @14 and the hung ceiling @15. VThe symbol a6 indicates a single or a monolithic partition, and a7 indicates a double or hollow partition.

A more detailed description will be given inr describing `the method used to obtain a flat surface of broken stone, slag, gravel, or other hard fireproof material over a backing of flat rolled steelor other metal, as follows:

` A flat sheet of metal is laid on a solid bed -in a kiln or other place suitable for reheating same, with the fireproof materials laid over or under same, or both over and under same as desired. Overhead a heavy ireproof press is placed in position so that it may be made to bear down evenly on the materials, with a stop for the press so arranged that it may move downward only for a given distance to obtain the exact penetration desired. The metal is then heated to a temperature where it will offer slight resistance to the penetration of the fireproof materials. he press is then lowered and when the operation is completed the metal is allowed to cool. Afterward the fireproof covering material is treated with other materials to form a finished building product. The same result may be obtained by pouring molten metal over ar surface of fireproof materials and then-press ing an additional layer of lireproofmaterials on top of the metal. The pressure maybe' exerted by a roller set to give4 an evenpressure to a certain depth, or by other similar means.

The process may also be used to press a bond or pattern of tile or brick or similar materials into a backing of metal, or by casting the backing over the materials, and-after the metal has cooledl the joints may be' pointed up with mortar or other materials to form a finished buildin g material.

The product of the process is hereinafter referred to as rough and finished fabric.

Various pieces of rough and finished ifabric may be joined together to Vform a -ho'llow wall section (Figures #l and 2) by means of angles, channels, sheets,.and.other metal members bolted, riveted, welded, or otherwise fastened to the edges of themetal backing of the fabric and to eachother. Additional bracing may be added to the interior f the hollow section, so rformed 4for extralateral bracing, and'for otherpurposes, to give the section a definite strength inany particular. An interior systen'iofreinforcing may be formed inside the sections should it be advisable to fill same with concrete or similar materials. Sound deadening, .insulation, or light fireproof material-s may be placed in the sectionsso formed. The metal backing of the fabric may be a `latticed or similarly designed plate .instead of a solid sheet, to save i meta-l.

Ornamental cornices, pilasters, projections, and the return at corners, jambs, sills, reveals, etc., (a1-a2-a3-a4-a5a8a9- L10-(L12 Figures .3f-'f5 and #6) vmay be made of strips of fabric joined together and to the hollow i Yall section, orlthey may be made by bending the fabric to the desired profile and fastening same tothe main body of the wall.

`When the wall sections are to be erected to form a. hollow wall the fabric for the back and front of the wall may be fastened together, as shownin F igurc #2, toform a continuous space all around thesections (c and e2) which may be reinforced and filled up with concrete to fireproof more substantially all of the lield oinings. This concrete containing a small sized aggregate of `stone `m ade hollow as shownfinligure #4.

and a secondary aggregate of small pieces of wire from one half to six inches long. Or the connections may be made as shown in Figure #l by placing the connecting plates 20 and 2l at the top and bottom of the sections so that they may be readily bolted, ri eted, welded or otherwise fastened to each other inthe field, smalllillerpieces of steel being interposed between the sections to allow space for a mortar joint. If a solid con- .creteibacking is desired, only the exterior facing may be formed of fabric as shown in Figure fjgt. EPartofthe reinforcing shown r(Z andm) may be welded to the backiner of the'fabric (04) and the balance put in p ace in the field. The hollow space S3 may be filled i up with .insulating materials, and the reinforcing 14 which isfastened to lthebacking c4; servesnearly the same, purpose asthe :rough fabric.

designed and -madeto `'envelop the wall fcolumns. ;I11,1einforced concrete structures the wall columns may be-poured 1ns1de=the wall sections in yspaces )provided ;forthem.

Partitions are madeeither of one flatsec- `tion of fabric for :of Ahollow construction similartofthewalls buton a smaller scale (Figure 7). For interiorpartitions theffabric is made in long sheets toiextend ifrom floor to ceiling or between supports. lfthe hollow construction -is used :light vertical angles maybe erectedin between the fabric facings, and the fabric facingsmay befastened tothe angleswhichfinturn may be fas- Vtened toitheioor andy ceiling.

*Floor` slabs-are made inithe samegcneral i manner aszthe hollowtpartitions, the; top. slab .acting as :a late-ral'tie anda bed forfthe finished-flooring, and thebottom slab actingV as a lateral A'tie `and a hungV ceiling. Between the top-andtbottom slabs and fastenedtherevto are :light vstructural steel members designed for .the purpose of carrying the'floor load between supports. `Wire lath maybe used for the hung ceiling,'instead of fabric.

The beams, girders and columns are likewise formed Vfrom sheets of fabric and struc turalsteelimembers may be used toV give a d dit-ional strength to the hollow sections, or they may be reinforced and filled-up .with concrete either before or after erection :in .the field.

In general all of the materialto be used on the exterior of a building would be finished in the shop and the interior work would be plastered after erection in the field, but the exterior may be finished after erection in the field and the interior work may be given special finishes in the shop.

Where reheating of the metal backing would be made prohibitive by local restric tions an ext-ra sheet of rolled steel or a structural steel member may be welded to the metal backing of the fabric to give it any necessary strength. During the process of making the fabric, or after cooling, the metal backing may be rolled, or otherwise' treated in any practicable manner to increase or maintain its ultimate tensile strength.

The fabric sheets may be wrapped around wood or other non-fireproof materials, or fastened to same to obtain a ireproof covering, or they may .be fastened to masonry work or backed up with same inthe usual manner. Where extra large units of fireproof materials are to be backed up with' metal a series of holes may be cut, in the back of the unit, and filled up with molten metal to which may be fastened additional metal to form a complete backing. In pouring molten metal over a layer of brick or tile the back of each unit may be cut away or the units may be otherwise treated to give them a better bond with the metal backing, temporary sand joints being used to avoid the use of unnecessary metal. f

From the foregoing it may be readily seen that I have evolved a new and unique method of making building materials of highly fire resistant materials strongly combined with, skillfully designed metal, and that anyone acquainted with the art could readily fabricate and erect a complete structure, using the above materials only or by using the above mentioned materials in combination with other materials. The material or the peculiar method of combining hard ireproof materials with metal will have many uses other than those outlined above. For one thing a heavy thickness of mixed steel and stone such as I have described hereinbefore would make an excellent material for a vault. It would also oEer unusual resistance to an ordinary projectile. The metal could completely enclose the stone or other material.

I claim 1. A building unit comprising two equally dimensioned parallel slabs in relative spaced alignment each slab having an exposed facing of spaced particles of building material with a cementitious filling moulded solidly in the outer portion of the spaces or joints between said particles and a metal matrix moulded solidly in the inner portion of the spaces between said particles and over the backs thereof forming a solid continuity of metal extending to the side and end edges of the aforesaid slabs, intermediary connecting members fastened to the metal backing of both slabs holding them rigidly in spaced relation, and means in the unit for assembling same togetherwith other similar units in a building structure.

2. A building unit comprising two equally dimensioned parallel slabs in relative spaced alignment each slab having an exposed facing of stucco or like material with spaced concrete aggregates or the like partly embedded in the back portion of the said stucco and a metal matrix moulded solidly in the spaces between the remaining parts of the embedded aggregates and over the backs thereof forming a solid continuity of metal extending to the side and end edges of the aforesaid slabs, intermediary connecting members fastened to the metal backing of both slabs holding them rigidly in spaced relation, and means in the unit for assembling same together with other similar units in a building structure.

Signed at 'Tt/:141 West 67th (Street, New York city, in the county of New York and State of New York this 12th day of May A. D. 1927. Y

JOHN JAMES OREILLY.

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